U.S. patent application number 16/470599 was filed with the patent office on 2020-03-19 for configurable optical connector.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Sergio D. Carranza, Daniel F. Cronch, Michael A. Haase, Boon K. Lee, Terry L. Smith.
Application Number | 20200088953 16/470599 |
Document ID | / |
Family ID | 60943070 |
Filed Date | 2020-03-19 |
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United States Patent
Application |
20200088953 |
Kind Code |
A1 |
Cronch; Daniel F. ; et
al. |
March 19, 2020 |
CONFIGURABLE OPTICAL CONNECTOR
Abstract
An optical connector (100) comprises one or more optical cables
(110) disposed within a housing (120). Each optical In cable (110)
includes an array of at least one optical waveguide (111) and at
least one optical ferrule (112) attached to the array of optical
waveguides (111). The housing (120) includes a first housing
portion (121) and a second housing portion (122) engaged with the
first housing portion (121). The second housing portion (122)
comprises at least one carrier (130) and one frame (140). The
carrier (130) and frame (140) of the second housing portion (122)
are configured to support the one or more optical cables (110). The
first housing portion (121) and the second housing portion (122)
are configured such that mechanical engagement of the first housing
portion (121) with the second housing portion (122) moves the
carrier (130) relative to the frame (140). Movement of the carrier
(130) relative to the frame (140) causes a bend in each optical
waveguide (111) and rotation of each ferrule (112). The bend
provides a predetermined spring force of the optical waveguides
(111) at a predetermined angle of the ferrule (112).
Inventors: |
Cronch; Daniel F.; (Denver,
CO) ; Carranza; Sergio D.; (Austin, TX) ; Lee;
Boon K.; (Leander, TX) ; Haase; Michael A.;
(St. Paul, MN) ; Smith; Terry L.; (Roseville,
MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St. Paul |
MN |
US |
|
|
Family ID: |
60943070 |
Appl. No.: |
16/470599 |
Filed: |
December 18, 2017 |
PCT Filed: |
December 18, 2017 |
PCT NO: |
PCT/IB2017/058074 |
371 Date: |
June 18, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62438536 |
Dec 23, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G02B 6/3885 20130101;
G02B 6/3821 20130101; G02B 6/3839 20130101; G02B 6/3878 20130101;
G02B 6/383 20130101; G02B 6/3829 20130101 |
International
Class: |
G02B 6/38 20060101
G02B006/38 |
Claims
1-10. (canceled)
11. An optical connector comprising: one or more optical cables,
each optical cable comprising an array of at least one optical
waveguide and at least one optical ferrule attached to the array of
optical waveguides; and a housing comprising: a first housing
portion; and a second housing portion engaged with the first
housing portion, the second housing portion comprising at least one
carrier and a frame, the carrier and frame of the second housing
portion configured to support the one or more optical cables, the
first housing portion and the second housing portion configured
such that mechanical engagement of the first housing portion with
the second housing portion moves the carrier relative to the frame,
movement of the carrier relative to the frame causing a bend in
each optical waveguide and rotation of each ferrule, the bend
providing a predetermined spring force of the optical waveguide at
a predetermined angle of the ferrule.
12. The optical connector of claim 11, wherein: at least one cable
retainer is attached to the array of waveguides of the one or more
optical cables and spaced apart from ferrules of the optical
cables; and the carrier includes at least one retainer mount
configured to receive the at least one cable retainer.
13. The optical connector of claim 12, wherein: the at least one
cable retainer comprises multiple cable retainers; and the one or
more optical cables comprises multiple optical cables, wherein each
of the multiple cable retainers is respectively attached to the at
least one waveguide of one of the multiple optical cables.
14. The optical connector of claim 11, wherein; the one or more
optical cables includes multiple optical cables, each optical cable
comprising a cable retainer attached to the array of waveguides of
the optical cable and spaced apart from the ferrule of the optical
cable; and the carrier includes multiple retainer mounts, each
retainer mount configured to receive a corresponding cable retainer
of the multiple optical cables.
15. The optical connector of claim 11, wherein the frame includes
one or more ferrule supports disposed at a mating end of the
optical connector, the ferrule supports configured to support the
ferrules of the optical cables.
16. The optical connector of claim 11, wherein the one or more
optical cables includes at least four optical cables, the optical
cables extending along a longitudinal axis of the connector and
stacked within the connector housing along a vertical axis
different from the longitudinal axis.
17. The optical connector of claim 11, wherein the frame includes
one or more frame waveguide support walls disposed between a mating
end of the optical connector and the carrier, each frame waveguide
support wall configured to support a corresponding optical
waveguide.
18. The optical connector of claim 11, wherein: the housing is
configured to allow insertion of the optical cables into the
carrier and the frame before engagement of the first housing
portion and the second housing portion while waveguides of the
optical cables are substantially straight or slightly bent; and
mechanical engagement of the first housing portion with the second
housing portion causes the waveguides to bend or to bend more.
19. The optical connector of claim 11, wherein: the frame and the
carrier are configured to allow insertion of the optical cable into
the frame and the carrier along a first insertion axis and a second
insertion axis orthogonal to the first insertion axis before
mechanical engagement of the first housing portion and the second
housing portion; and mechanical engagement of the first housing
portion with the second housing portion causes the carrier to move
relative to the frame along a configuration axis that is different
from the first insertion axis and the second insertion axis.
20. The optical connector of claim 11, wherein the first housing
portion and the second housing portion are configured such that
mechanical engagement of the first and second housing portions
includes rotational movement of the first housing portion and the
second housing portion around a rotational engagement axis.
21. An optical connector comprising: one or more optical cables
each optical cable comprising an array of at least one optical
waveguide and at least one optical ferrule attached to the array of
optical waveguides; a housing comprising at least one carrier and a
frame, the carrier and the frame configured to support the one or
more optical cables; and an actuator configured such that operation
of the actuator causes relative motion between the carrier and the
frame, the relative motion between the carrier and the frame
causing a bend in the optical waveguide and rotation of the
ferrule, the bend providing a predetermined spring force of the
waveguide at a predetermined angle of the ferrule with respect to a
mating axis of the optical connector.
22. The optical connector of claim 21, wherein the housing includes
a first housing portion and a second housing portion engaged with
the first housing portion, the second housing portion comprising
the carrier and the frame.
23. The optical connector of claim 21, wherein: the carrier and the
frame are configured to allow insertion of the optical cables into
the frame and the carrier along a first insertion axis and a second
insertion axis orthogonal to the first insertion axis before the
mechanical engagement of the first housing portion and the second
housing portion; and the actuator is configured such that operation
of the actuator causes the carrier to move relative to the frame
along a configuration axis, wherein: the first insertion axis is a
lateral axis substantially orthogonal to a mating axis of the
optical connector and the second insertion axis is a longitudinal
axis substantially parallel to the mating axis of the optical
connector; and the configuration axis is a vertical axis
substantially orthogonal to the mating axis.
24. An optical connector comprising: one or more optical cables,
each optical cable comprising am array of at least one optical
waveguide and at least one optical ferrule attached to the optical
waveguide; and a housing that includes one or more waveguide
support walls, each waveguide support wall configured to allow the
optical cables to be inserted into the housing when waveguides of
the optical cables are in a substantially straight configuration,
each waveguide support wall having a sloped surface to support the
waveguides at a predetermined angle to a mating axis of the optical
connector after the waveguides bend within the housing.
25. The optical connector of claim 24, wherein the housing includes
a carrier and a frame configured to move relative to one another,
movement of the carrier relative to the frame causing the
waveguides to bend.
26. The optical connector of claim 25, wherein the waveguide
support walls are disposed in one or both of the carrier and the
frame.
27. The optical connector of claim 25, wherein: each optical cable
includes a cable retainer spaced apart from the ferrule and
attached to the waveguide; and the carrier includes at least one
retainer mount configured to receive the cable retainer.
28. The optical connector of claim 27, wherein: the housing
includes a carrier and a frame configured to move relative to one
another; and the retainer mount is disposed in the carrier such
that movement of the carrier relative to the frame causes the
waveguides to bend.
29. The optical connector of claim 24, wherein the housing
comprises: a first housing portion; and a second housing portion
engaged with the first housing portion, the second housing portion
comprising a carrier and the frame configured to move relative to
one another, engagement of the first housing portion with the
second housing portion causing the relative movement of the carrier
and the frame, the relative movement of the carrier and the frame
causing the waveguides to bend within the housing.
30. The optical connector of claim 24, wherein each waveguide
support wall includes a face that is spaced apart from a mating
face of the optical connector.
Description
TECHNICAL FIELD
[0001] This disclosure relates generally to optical connector
assemblies and methods related to optical connector assemblies.
BACKGROUND
[0002] Optical connectors can be used for optical communications in
a variety of applications including telecommunications networks,
local area networks, data center links, and internal links in
computer devices. There is interest in extending optical
communication to applications inside smaller consumer electronic
appliances such as laptops and even cell phones. Expanded optical
beams may be used in connectors for these systems to provide an
optical connection that is less sensitive to dust and other forms
of contamination and so that alignment tolerances may be relaxed.
Generally, an expanded beam is a beam that is larger in diameter
than the core of an associated optical waveguide (usually an
optical fiber, e.g., a multi-mode fiber for a multi-mode
communication system). The connector is generally considered an
expanded beam connector if there is an expanded beam at a
connection point. The expanded beam is typically obtained by
diverging a light beam from a source or optical fiber. In many
cases, the diverging beam is processed by optical elements such as
a lens or mirror into an expanded beam that is approximately
collimated. The expanded beam is then received by focusing of the
beam via another lens or mirror. These expanded beam optical
connectors can have non-contact optical coupling and require
reduced mechanical precision when compared with conventional
optical connectors.
BRIEF SUMMARY
[0003] Some embodiments are directed to an optical connector
comprising one or more optical cables disposed within a housing.
Each optical cable includes at least one optical waveguide and at
least one optical ferrule attached to the optical waveguide. The
housing includes a first housing portion and a second housing
portion engaged with the first housing portion. The second housing
portion comprises at least one carrier and one frame. The carrier
and frame of the second housing portion are configured to support
the one or more optical cables. The first housing portion and the
second housing portion are configured such that mechanical
engagement of the first housing portion with the second housing
portion moves the carrier relative to the frame. Movement of the
carrier relative to the frame causes a bend in each optical
waveguide and rotation of each ferrule. The bend provides a
predetermined spring force of the optical waveguide at a
predetermined angle of the ferrule.
[0004] According to some embodiments, the optical connector as
described above includes an actuator configured such that operation
of the actuator causes relative motion between the carrier and the
frame. The relative motion between the carrier and the frame causes
the bend in the optical waveguide and rotation of the ferrule.
[0005] Some embodiments are directed to an optical connector that
includes one or more optical cables and a housing. Each optical
cable comprises at least one optical waveguide and at least one
optical ferrule attached to the optical waveguide. The housing
includes one or more waveguide support walls. Each waveguide
support wall is configured to allow the optical cables to be
inserted into the housing when waveguides of the optical cables are
in a substantially straight configuration. Each waveguide support
wall has a sloped surface to support the waveguides at a
predetermined angle to a mating axis of the optical connector after
the waveguides bend within the housing.
[0006] According to some embodiments, an optical connector includes
one or more optical cables, each optical cable comprising at least
one optical waveguide and at least one optical ferrule attached to
the optical waveguide. The optical cables are disposed in a housing
of the connector. The housing includes one or more waveguide
support walls configured to support the optical cables. The one or
more waveguide support walls are configured to allow the optical
cables to be inserted into the housing along a direction
substantially orthogonal to a mating axis of the optical
connector.
[0007] Some embodiments are directed to an optical cable. The
optical cable includes at least one optical waveguide having a
longitudinal axis. At least one optical ferrule is attached to the
optical waveguide. A cable retainer is attached to the optical
waveguide and spaced apart from the ferrule. The optical cable is
configured such that when the optical waveguide is held by the
cable retainer so that the portion of the optical waveguide at the
cable retainer is horizontally straight with respect to gravity,
the portion of the optical waveguide at the ferrule sags by less
than a predetermined percentage, x %, of a distance, d, between the
cable retainer and the optical ferrule.
[0008] Some embodiments are directed to a method of assembling an
optical connector. One or more optical cables are inserted into a
housing comprising a carrier and frame. Each optical cable
comprises at least one optical waveguide and at least one optical
ferrule attached to the optical waveguide. An actuator is operated
which causes relative movement between the carrier and the frame.
In response to the relative movement between the carrier and the
frame, the optical waveguide bends and the ferrule rotates. The
bending of the optical waveguide provides a predetermined spring
force at a predetermined angle of the ferrule.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1A shows an partially transparent perspective view of a
connector comprising a first housing portion and a second housing
portion after engagement of the first and second housing portions
in accordance with some embodiments;
[0010] FIG. 1B shows the second housing portion of the connector of
FIG. 1A;
[0011] FIG. 1C is a perspective view of the connector of FIG. 1A
during engagement of the first housing portion and the second
housing portion;
[0012] FIG. 1D is a perspective view of the connector of FIG. 1A
after engagement of the first housing portion and the second
housing portion of the connector of FIG. 1A;
[0013] FIGS. 1E and 1F illustrate insertion of the optical cables
into the second housing portion of the connector of FIG. 1A;
[0014] FIG. 1G illustrates the optical cables after engagement of
the first and second housing portions of the connector of FIG.
1A;
[0015] FIG. 2A depicts an optical cable that can be used in optical
connectors in accordance with some embodiments;
[0016] FIG. 2B illustrates the gravitationally-induced bending
(sag) of the optical cable of FIG. 2A when held horizontally and
perpendicular to the force of gravity;
[0017] FIG. 2C illustrates an optical cable comprising one cable
retainer attached to two sets of optical waveguides, each set of
optical waveguides attached to a different ferrule in accordance
with some embodiments;
[0018] FIG. 2D is a cutaway view of a portion of a ferrule focusing
on the light redirecting member of the ferrule in accordance with
some embodiments;
[0019] FIG. 2E illustrates a side view of two optical cables
showing mated ferrules in accordance with some embodiments;
[0020] FIG. 3A illustrates an optical connector having a monolithic
carrier in accordance with some embodiments;
[0021] FIG. 3B shows the second housing portion of the connector of
FIG. 3A;
[0022] FIG. 4A is a perspective view of an optical connector in
accordance with some embodiments;
[0023] FIG. 4B is a partially see-through view of the first and
second housing portions of the connector of FIG. 4A;
[0024] FIG. 5A shows a partially see through view of an optical
connector in accordance with some embodiments;
[0025] FIGS. 5B and 5C show operation of the actuator of the
connector of FIG. 5A; and
[0026] FIG. 6 is a flow diagram illustrating a method of
implementing an optical connector in accordance with some
embodiments.
[0027] The figures are not necessarily to scale. Like numbers used
in the figures refer to like components. However, it will be
understood that the use of a number to refer to a component in a
given figure is not intended to limit the component in another
figure labeled with the same number.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0028] Optical connectors described herein include one or more
optical cable assemblies disposed in a housing. The optical cable
assemblies may comprise one waveguide or arrays of multiple
parallel waveguides (typically 4, 8 or 12 or more parallel
waveguides) attached to one or more optical ferrules. Optical
connectors described herein include use optical cable assemblies
having waveguides that are bent. The bend in the waveguides
provides a predetermined mating force for optical ferrules.
Assembly of optical connectors that include bent optical waveguides
can be simplified when the optical waveguides are inserted into the
housing in a substantially straight or less bent configuration and
the waveguides are subsequently bent or bent more within the
housing after insertion. Embodiments described below involve
connectors in which one more optical cables can be inserted into
the connector housing in a substantially straight or less bent
configuration. After insertion of the optical cables into the
connector housing, the connector is configured by moving a first
portion of the connector housing relative to a second portion or
the connector housing. Movement of the first portion of the
connector housing relative to the second portion of the connector
housing causes the optical waveguides of the optical cables to bend
and/or bend more and the optical ferrules attached to the optical
waveguides to rotate. The bend in the optical waveguides provides a
predetermined spring force of the optical waveguides at a
predetermined angle of the ferrules.
[0029] FIGS. 1A-1G depict various aspects and components of an
optical connector 100 in accordance with some embodiments. The
connector 100 includes optical cables 110 disposed within a housing
120 and comprising a first housing portion 121 and a second housing
portion 122 engaged with first housing portion 121. FIG. 1B shows
the second housing portion 122. FIG. 1A shows a partially
transparent perspective view of the connector 100 comprising the
first 121 and second 122 housing portions after partial
engagement.
[0030] The one or more optical cables 110 are disposed partially
within the housing 120. Each optical cable 110 includes a waveguide
array 111 comprising one or more optical waveguides attached to at
least one optical ferrule 112. The optical waveguides may be
optical fibers, e.g., single-mode fibers or multi-mode fibers, or
planar waveguides disposed on a substrate. The individual
waveguides of the waveguide array 111 are typically optical fibers
made of glass with a protective buffer coating. Multiple parallel
waveguides of a waveguide array 111 may be enclosed by a
jacket.
[0031] In some embodiments, as shown in FIGS. 1A and 1B, an optical
connector 100 includes four optical cables 110, wherein each
optical cable assembly includes a waveguide array 111 comprising
one or more waveguides and one optical ferrule 112. The connector
100 is shown oriented with respect to three orthogonal axes,
longitudinal axis 196, lateral axis 197, and vertical axis 198,
wherein the names of the axes are used for convenience and do not
imply any specific orientation of the connector in space. The
optical cables 110 generally extend in a direction along, or
slightly skewed to, the mating axis 199 of the optical connector
100 and can be stacked within the housing 120 of the optical
connector 100 along connector vertical axis 198 which is orthogonal
to the mating axis 199.
[0032] FIG. 1B shows the second housing portion 122 which is
configured to support the one or more optical cables 110. The
second housing portion 122 includes a frame 140 and one or more
carriers 130 that support the optical cables 110. The one or more
carriers 130 and optical cables 110 are disposed at least partially
within the frame 140. Although the connector 100 shown in FIG. 1B
has one frame and one carrier 130, according to various
embodiments, an optical connector may include one frame or multiple
frames and/or may include one carrier or multiple carriers.
[0033] The view shown in FIG. 1B depicts the second portion 122 of
the housing 120 prior to engagement with the first housing portion
121. The second housing portion 122 comprises a carrier 130 and
frame 140 configured to support the optical cables 100. In FIG. 1B,
the optical cables 110 have been inserted into the carrier 130 and
frame 140 and are in a substantially straight configuration. The
first housing portion 121 (see FIG. 1A) and the second housing
portion 122 (see FIGS. 1A and 1B) are configured such that
mechanical engagement of the first housing portion 121 with the
second housing portion 122 moves the carrier 130 relative to the
frame 140 along the axis 198. FIG. 1A shows a perspective view of
the connector 100, including first housing portion 121 and the
second housing portion 122, after engagement. The movement of the
carrier 130 relative to the frame 140 causes a bend 111a in each
optical waveguide of the waveguide array 111 and causes each
ferrule 112 to rotate. The bend 111a provides a predetermined
spring force of the optical waveguide array 111 at a predetermined
angle of the ferrule 112.
[0034] The connector 100 includes multiple optical cables 110, each
optical cable including at least one cable retainer 113. The cable
retainer 113 is attached to the waveguide array 111 of the optical
cable 110, e.g., by adhesive or friction grip, and is spaced apart
from the ferrule 112. The second housing portion 122 comprises a
carrier 130 that includes at least one retainer mount 143
configured to receive the cable retainer 113. As depicted in FIGS.
1A through 1G, the carrier 130 of the second housing portion 122
may include multiple retainer mounts 143 wherein each retainer
mount 143 is configured to receive a corresponding cable retainer
113.
[0035] The relationship between the number of cable retainers and
the number of optical cables may be one-to-one as illustrated in
FIGS. 1A through 1G. Alternatively, in some embodiments, the number
of cable retainers may be less than the number of optical cables.
For example, as illustrated in FIGS. 2C one cable retainer 113c may
be attached to two optical waveguide arrays 111c-1 and 111c-2, that
are in turn attached to different ferrules 112c-1 and 112c-2, in
accordance with some embodiments. Referring again to the embodiment
illustrated in FIGS. 1A through 1E, the frame 140 includes one or
more ferrule supports 150 (see FIG. 1E) disposed at a mating end
180 of the optical connector 100. The ferrule supports 150 are
configured to support the ferrules 112 of the optical cables 110.
The frame 140 includes one or more frame waveguide support walls
141 disposed between a mating end 180 of the optical connector 100
and the carrier 130. Each frame waveguide support wall 141 is
configured to support a corresponding optical waveguide array 111.
The waveguide array may include one or more waveguides. As shown in
FIG. 1B, each frame waveguide support wall 141 includes a sloped
portion 141a that supports the optical waveguide 111 such that the
optical waveguide 111 makes a predetermined angle .theta. with
respect to a mating axis 199 of the optical connector 100. The
predetermined angle .theta. may be between 15 and 25 degrees or
about 18 degrees, for example.
[0036] As best seen in FIG. 1A, the carrier 130 may also include
one or more carrier waveguide support walls 131 that are disposed
between the mating end 180 of the optical connector and the
retainer mount 143. Each carrier waveguide support wall 131 is
configured to support a corresponding optical waveguide array 111.
Each carrier waveguide support wall 131 can include a sloped
surface 131a that supports the optical waveguide array 111 such
that the optical waveguide array 111 makes a predetermined angle
.theta. with respect to a mating axis 199 of the optical connector
100. The predetermined angle .theta. may be between 15 and 25
degrees or about 18 degrees for example.
[0037] The connector 100 is assembled by first inserting the
optical cables 110 into the carrier 130 and frame 140 of the second
housing portion 122 in a substantially straight or less bent
configuration. After insertion of the optical cables 110, the first
121 and second 122 housing portions are engaged. In the embodiment
represented by FIGS. 1A through 1G, engagement of the first 121 and
second 122 housing portions causes the carrier to move relative to
the frame along the axis 198. The relative movement of the carrier
130 and frame 140 causes the optical waveguide array 111 to bend or
bend more and causes the optical ferrules 112 to rotate. FIG. 1C is
a perspective view of the connector 100 during engagement of the
first housing portion 121 and the second housing portion 122. FIG.
1D is a perspective view of the connector 100 after engagement of
the first housing portion 121 and the second housing portion 122.
FIGS. 1E and 1F illustrate insertion of the optical cables 110 into
the second housing portion 122. FIG. 1G illustrates the optical
cables 110 after engagement of the first 121 and second 122 housing
portions.
[0038] As best seen in FIGS. 1E and 1F, before engagement of the
first 121 and second 122 housing portions the carrier 130 and the
frame 140 are adapted to allow the optical cables 110 to be
installed in and subsequently removed from the carrier 130 and the
frame 140 without damage to the second housing portion 122,
including the carrier 130 and frame 140, and/or the optical cables
110. The optical cables 110 can be inserted into the carrier 130
and the frame 140 before engagement of the first housing portion
121 and the second housing portion 122 while waveguide array 111 of
the optical cables 110 is substantially straight or slightly bent.
The assembly of the connector 100 includes configuring the
connector. Configuring the connector includes the operation that
causes the waveguide array 111 to bend or bend more and causes the
ferrules 112 to rotate. For the connector 100 shown in FIGS. 1A
through 1G, configuration of the connector occurs when the first
and second housing portions are engaged. Engagement of the first
and second housing portions causes the carrier 130 to move relative
to the frame 140. The relative movement causes the waveguide array
111 to bend or to bend more, as depicted in FIG. 1G.
[0039] The optical cables 110 may be inserted into the carrier and
frame along one or more insertion axes. Referring to FIGS. 1E and
1F, in some configurations the optical cables 110 are inserted into
the carrier 130 and the frame 140 of the second housing portion 122
along at least a first insertion axis. In some configurations, the
optical cables 110 are inserted into the carrier 130 and frame 140
of the second housing portion 122 along first, seconds, and/or
third orthogonal insertion axes.
[0040] In the embodiment shown in FIGS. 1E and 1F, the optical
cable assemblies are inserted into carrier 130 and frame 140 along
first and second insertion axes that are orthogonal to one another.
The first insertion axis, e.g., connector lateral axis 197, is
substantially orthogonal to the mating axis 199 of the optical
connector 100. The second insertion axis, e.g., connector
longitudinal axis 196, is substantially parallel to the mating axis
199 and is orthogonal to the lateral axis 197. Insertion of the
optical cables 110 along the lateral axis 197 (first insertion
axis) and the longitudinal axis 196 (second insertion axis) causes
the ferrules 112 of the optical cables 110 to be inserted between
the ferrule supports 150 of the frame 140 and causes the cable
retainers 113 to be inserted into the retainer mounts 143 of the
carrier 130 as shown in FIG. 1F.
[0041] In the embodiment illustrated in FIGS. 1A through 1G, the
first and second housing portions 121, 122 are engaged after the
optical cables 110 are inserted in the second connector housing
portion 122. Installation of the optical cables 110 involves
insertion of the optical cables 110 along the lateral and
longitudinal axes 197, 196 (first and second insertion axes) as
described above. As illustrated in FIGS. 1C and 1D, engagement of
the first 121 and second 122 housing portions involves relative
movement between the first housing portion 121 and the second
housing portion 122 along at least a first engagement axis. As
shown in FIG. 1C, the engagement of the first and second housing
portions can involve movement along the lateral axis 197 that is
substantially perpendicular to the mating axis 199 in some
embodiments. As further shown in FIG. 1C, in some embodiments,
mechanical engagement of the first housing portion 121 and the
second housing portion 122 may involve relative rotational movement
of the first 121 and second 122 housing portions. For example, the
rotational movement can involve rotation around a rotational axis
198a (see FIG. 1C) that is substantially parallel to axis 198. The
rotational axis 198a may be substantially orthogonal to the mating
axis 199, as depicted in FIG. 1C. In other embodiments, the
rotational axis may be substantially parallel to the mating axis
199, for example.
[0042] In the connector illustrated in FIGS. 1A through 1G, the
first housing portion 121 and the second housing portion 122 are
configured such that the mechanical engagement of the first housing
portion 121 with the second housing portion 122 (see FIG. 1C and
FIG. 1G) causes the carrier 130 to move relative to the frame 140
along a configuration axis, e.g., connector vertical axis 198,
shown in FIG. 1G. In the embodiment illustrated in FIGS. 1E through
1G, the axis 198 (configuration axis) is substantially
perpendicular to the mating axis 199 of the optical connector 100
and is also substantially perpendicular to the lateral axis 197.
Movement of the carrier 130 relative to the frame 140 along the
vertical (configuration) axis 198 causes the waveguide array 111 of
the optical cables 110 to bend or bend more from their initial
position following insertion and causes the ferrules 112 attached
to the waveguide array 111 to rotate.
[0043] FIG. 2A depicts the optical cable 110 that can be used in
optical connectors in accordance with some embodiments. The optical
cable 110 comprises an array of one or optical waveguides 111 that
extend along a waveguide longitudinal axis 195. At least one
optical ferrule 112 is attached each optical waveguide array 111
and a cable retainer 113 is attached to the optical waveguide array
111 spaced apart from the ferrule 112. As illustrated in FIG. 2B,
when the optical cable 110 is supported and held horizontally
straight with respect to the force of gravity by the cable retainer
113, the optical waveguide 111 sags from the horizontal by less
than a predetermined percentage, x %, of the distance, d, between
the cable retainer 113 and the optical ferrule 112. Suitable values
for x % may be in a range between about 20% and about 1%. For
example, values for x % may be about 20%, about 10%, about 5%, or
about 1%. The distance, d, may be about 4 cm or about 1.8 cm in
some embodiments. Additional information regarding cable retainers
and retainer mounts and optical connectors that incorporate
retainers and mounts is discussed in commonly owned US. Patent
Application S/N 62/240008 identified by Attorney Docket No.
76662US002 filed on Oct. 12, 2015 which is incorporated herein by
reference. As previously discussed, the optical waveguide array 111
may comprise one optical fiber or multiple optical fibers. The at
least one optical waveguide array 111 can comprise at least one
planar waveguide disposed on a substrate or multiple planar
waveguides disposed on a substrate. The term optical waveguide is
used herein to refer to an optical element that propagates signal
light. An optical waveguide comprises at least one core with a
cladding, wherein the core and cladding are configured to propagate
light, e.g., by total internal reflection. An optical waveguide may
be, for example, a single or multi-mode waveguide, a single core
fiber, a multi-core optical fiber, or a polymeric waveguide. A
waveguide may have any suitable cross sectional shape, e.g.,
circular, square, rectangular etc.
[0044] The ferrule 112 is configured to mate, e.g.,
hermaphroditically, with another ferrule. The ferrule 112
illustrated in FIGS. 2A and 2B includes a mechanical mating tongue
116 and light redirecting member 115. In some embodiments, the
mechanical mating tongue 116 can have a tapering width along at
least a portion of a length of the tongue portion as shown in the
illustrations. The mechanical mating tongue 116 can extend
outwardly from a front of a connector housing (not shown in FIGS.
2A and 2B).
[0045] In some embodiments, multiple waveguide arrays may be
attached to a single cable retainer. FIG. 2C illustrates a cable
retainer 113c attached to multiple waveguide arrays 111c-1, 111c-2
that are shown extending along the waveguide longitudinal axis 195.
FIG. 2C shows the first waveguide array 111c-1 attached to ferrule
112c-1 and the second waveguide array 111c-2 attached to a second
ferrule 112c-2. Each of the first and second waveguide arrays
111c-1, 111c-2 are attached to a single cable retainer 113c.
[0046] FIG. 2D is a cutaway view of a portion of a ferrule 112
focusing on the light redirecting member. FIG. 2D illustrates the
attachment of several optical waveguides or a waveguide array 111
to ferrule portion 220. Optical waveguides 111 are aligned in
grooves 108 to which they are permanently attached. At the point of
attachment, the fiber buffer coating and protective jacket (if any)
of the waveguides 111 has been stripped away to allow only the bare
optical fibers to lie aligned and permanently affixed to grooves
108. The exit ends of optical waveguides in array 111 are situated
so as to be able to direct light emanating from each optical
waveguide in the optical waveguide array 111 into the input side or
face of corresponding light redirecting member 115. Ferrule portion
220 includes an array of light redirecting elements 117, at least
one for each optical waveguide in the waveguide array 111 attached
to ferrule 112. For example, in various embodiments each light
redirecting element 115 comprises one or more of a prism, a lens,
and a reflecting surface. Ferrule portion 220 includes an array of
light redirecting elements 117, one for each optical waveguide of
the optical waveguide (optical fiber) array 111
[0047] FIG. 2E illustrates a side view of two optical cables 110-1
and 110-2 showing mated ferrules 112-1, 112-2 having light coupling
members 115-1 and 115-2 and attached to optical waveguide arrays
111-1, 111-2 at light coupling unit attachment areas 118-1, 118-2.
A cable retainer 113-1, 113-2 is attached to the optical waveguide
arrays 111-1, 111-2. The ferrules 112-1, 112-2 may be oriented at a
predetermined mating angle, .quadrature., with respect to a mating
direction. A bend in the optical waveguide arrays 111-1, 111-2
between the light coupling unit attachment area 118-1, 118-2 and
the cable retainer 113-1, 113-2 provides a predetermined amount of
spring force to maintain the ferrules 112-1, 112-2 in the mated
position.
[0048] Additional information regarding features and operation of
light coupling units, optical cables and optical connectors is
discussed in commonly owned U.S. Patent Application 61/710,077
filed on Oct. 5, 2012 which is incorporated herein by reference in
its entirety.
[0049] FIGS. 3A and 3B illustrate an optical connector 300 that is
similar in many respects to the optical connector 100 shown in
FIGS. 1A through 1G. Optical connector 300 differs from connector
100 in that connector 300 includes a monolithic carrier 330 and
does not include separate cable retainers and retainer mounts as
shown in FIGS. 1A through 1G. The monolithic carrier 330 can be
attached directly to the waveguide arrays 111, e.g., by adhesive or
friction grip.
[0050] The connectors 100 and 300 shown in FIGS. 1A through 1G and
FIGS. 3A and 3B, respectively, include an actuator 170 that
configures the connector after the optical cable assemblies are
inserted into the housing. Operation of the actuator 170 causes
relative motion between the carrier 130, 330 and the frame 140,
along axis 198 (the configuration axis). The relative motion
between the carrier 130, 330 and the frame 140 along axis 198
causes a bend 111a in the waveguide array 111 of the optical cable
110 and causes the ferrules 112 to rotate. The bend 111a in the
waveguide array 111 provides a predetermined about of spring force
of the waveguide array 111 at a predetermined angle of the ferrules
112 with respect to the mating axis 199 of the connector 100,
300.
[0051] According to some implementations, the actuator 170 is
configured such that operation of the actuator 170 occurs when the
first housing portion 121 mechanically engages with the second
housing portion 122. As best seen in FIGS. 1A-1C, in some
embodiments the actuator 170 comprises an actuator rib 171 of the
first housing portion 121 and a carrier surface 172 of the carrier
130. The actuator rib 171 comprises a first rib surface 171a and an
angled rib surface 171b. The carrier surface 172 comprising a first
carrier surface 172a and an angled carrier surface 172b. The angled
surface of the rib 171b is complementary to the angled actuator
surface 172b. When the connector 100 is oriented as shown in FIG.
1A, surfaces 171a, 171b of the rib 171 are configured to interact
with the actuator surfaces 172a, 172b. The surfaces 171a, 171b
apply a force to the surfaces 172a, 172b, pushing the carrier 130
up along axis 198 (configuration axis) relative to the frame
140.
[0052] As shown in FIG. 1A, the second housing portion 122 may
include a retaining clip 182 having a ramped surface 182a. The
retaining clip 182 is configured to engage with a mating feature
183 of the first housing portion 121. Engagement of the retaining
clip 182 and the mating feature 183 holds the first housing portion
121 and second housing portions 122 together after they are fully
engaged.
[0053] FIG. 4A is a see-through perspective view of the housing 420
illustrating first 421 and second 422 housing portions that are
fully engaged. FIG. 4B is an exploded perspective view of connector
400 comprising a housing 420 that includes first 421 and second 422
housing portions. The second housing portion 422 includes a carrier
430 and frame 440 wherein the carrier 430 and frame 440 are
configured to move relative to one another during mechanical
engagement of the first 421 and second 422 housing portions. The
carrier 430 includes one or more retainer mounts 443 configured to
receive cable retainers of the optical cables as previously
discussed. As indicated in FIGS. 4A and 4B, the frame 440 includes
one or more ferrule supports 450 disposed at a mating end 480 of
the optical connector 400. The ferrule supports 450 are configured
to support the ferrules 412 of the optical cables disposed within
the connector housing 420 as previously discussed. Connector 400
includes an actuator 470 that, when operated by engagement of the
first 421 and second 422 housing portions, causes relative movement
between the carrier 430 and frame 440. As illustrated in FIGS. 4A
and 4B, the actuator 470 comprises a tapered surface 471 of the
first housing portion 421 that is configured to engage with a
surface 472 of the carrier 430. Engagement of the tapered surface
471 of the first housing portion 421 with the surface 472 of the
carrier 430 causes the carrier 430 to move relative to the frame
440 along the axis 198 (configuration axis).
[0054] Engagement of the first housing portion 421 and the second
housing portion 422 involves inserting the second housing portion
into the cavity 420a of the first housing portion 421 through the
opening 420b of the first housing portion 421. During engagement of
the first and second housing portions 421, 422 the second housing
portion 422 engages with the first housing portion 421 along
longitudinal axis 196 which is substantially parallel to the mating
axis 199. Interaction of the tapered surface 471 of the first
housing portion 421 with the carrier surface 430a along the
longitudinal (engagement) axis 196 causes the relative motion
between the carrier 430 and frame 440 along configuration axis 198.
As the second housing portion 422 slides into the cavity 420a of
the first housing portion 421, the tapered surface 471 interacts
with the surface 472 of the carrier 430 forcing the carrier 430 to
move along axis 198.
[0055] The actuators 170, 470 illustrated in FIGS. 1A through 1G,
3A, 3B, 4A and 4B are operated to move the carrier 130, 430
relative to the frame 140, 440 as the first housing portion 121,
421 engages with the second housing portion 122, 422. In
alternative embodiments, the operation of the actuator that causes
the relative motion between carrier and the frame is independent of
the engagement of the housing portions.
[0056] FIGS. 5A through 5C illustrate a connector 500 having
actuator 570 capable of being operated independently of the
engagement of the first 521 and second 522 housing portions. FIG.
5A shows an partially see through view of the first and second
housing portions 521, 522 and optical cables 110. Each optical
cable 110 includes an optical waveguide array 111 comprising at
least one optical waveguide attached to a ferrule 112. The first
and second housing portions 521, 522 can be engaged before
operation of the actuator 570. The housing 520 includes a carrier
530 and frame 540. The carrier 530 includes retainer mounts 543
configured to receive and hold the cable retainers 113
[0057] In the embodiment illustrated in FIGS. 5A through 5C, the
actuator 570 includes a cam 571 disposed within the housing 520 and
configured to rotate around a pivot 572. Although the cam 571 is
shown to be a part of the first housing portion 521 in FIG. 5A, the
cam could alternatively be located on the second housing portion.
Rotation of the cam 571 causes the cam 571 to engage with a surface
530a of the carrier 530, forcing the carrier 530 to move relative
to the frame 540 along axis 198 (configuration axis). Movement of
the carrier 530 relative to the frame 540 causes the optical
waveguide array 111 to bend and the ferrules 112 to rotate. The
bend 111a in the optical waveguide array 111 provides a
predetermined amount of mating spring force at a predetermined
angle of the ferrules 112 when the ferrules 112 are mated with a
mating ferrule.
[0058] The actuators 170, 470, 570 discussed herein can be
configured to be reversibly operated. Operation of the actuator
170, 470 of connectors 100, 400 occurs when the first housing
portion 121, 421 engages with the second housing portion 122, 422.
Operating the actuator 170, 470 of connectors 100, 300, 400, causes
the carrier 130, 430 to move relative to the frame 149, 440 from an
initial carrier/frame position (see FIG. 1B) to a second
carrier/frame position (see FIG. 1A) which in turn causes the
optical waveguide array 111, 411 to bend or bend more. Reversing
the operation of the actuator 170, 470 of connectors 100, 300, 400
involves disengaging the first housing portion 121, 421 from the
second housing portion 122, 422. Reversing the operation of the
actuator 170, 470 causes the carrier 130, 430 and frame 140, 440 to
move from the second carrier/frame position back to the initial
carrier/frame position wherein the optical waveguides are in a less
bent or substantially straight configuration. The optical waveguide
array 111, 411 can be removed from the carrier and frame without
substantial damage to the waveguide array 111, 411, the carrier
130, 430, and/or the frame 140, 440.
[0059] Operation of actuator 570 of connector 500 occurs when the
cam 571 is rotated from an initial cam position (shown in FIG. 5B)
to a second cam position (shown in FIG. 5C). Rotation of the cam
571 forces the carrier 530 to move relative to the frame 540 from
an initial carrier/frame position where the optical waveguide array
111 is in a less bent or a substantially straight configuration to
a second carrier/frame position where the optical waveguide array
511 is bent or are bent more. Reversing the operation of the
actuator 570 involves rotating the cam 571 from the second cam
position back to the initial cam position which allows the carrier
530 to move from the second carrier/frame position back to the
initial carrier/frame position.
[0060] The actuator that causes the carrier to move relative to the
frame can have actuator portions disposed on the first housing
portion, the second housing portion or on both first and second
housing portions. As discussed above, operation of the actuator can
depend on the engagement of the first and second housing portions
or can be independent of the engagement of the first and second
housing portions. For example, the actuator can be operated
manually via an external knob or screw head. Operation of the
actuator can be reversible or irreversible. Before the actuator is
operated to move the carrier relative to the frame, the carrier and
the frame are adapted to allow the optical cables to be installed
in and subsequently removed from the second housing portion in a
substantially straight or slightly bent configuration without
damage to the second housing portion and/or to the optical
cables.
[0061] According to some embodiments, the optical connector 100,
300, 400, 500 includes a housing 120, 420, 520 comprising one or
more waveguide support walls 131, 141, 331, 341, 431, 441, 531, 541
configured to support the optical cables 110, 410, 510. The
waveguide support walls 131, 141, 431, 441, 531, 541 may disposed
on the carrier 130, 430, 530 and/or the frame 140, 440, 540 of the
connector housing 120, 420, 520. Each waveguide support wall 131,
141, 431, 441, 531, 541 includes a face 131c, 141c, 331c, 341c,
431c, 441c, 531c, 541c that is spaced apart from a mating face 181,
481, 581 of the optical connector 100, 300, 400, 500. The one or
more waveguide support walls 131, 141, 331, 341, 431, 441, 531, 541
are configured to allow optical cables 110, 410, 510 to be inserted
into the housing 120, 420, 520 along a direction substantially
orthogonal to a mating axis 199 of the optical connector 100, 300,
400, 500.
[0062] As shown in FIGS. 1A, 1B, 3A, 3B, 4A, 4B, 5A, 5B each
waveguide support wall 131, 141, 431, 441, 531, 541 includes at
least one sloped surface 131a, 141a, 431a, 441a, 531a, 541a
configured to support the optical waveguide array 111, 411, 511 of
the optical cable 110, 410, 510 at a predetermined angle, .theta.,
with respect to a mating axis 199 of the optical connector 100,
300, 400, 500. For example, the predetermined angle, .theta., may
be between about 15 and about 25 degrees. In some implementations,
the predetermined angle is about 18 degrees. The waveguide support
walls 131, 141, 431, 441, 531, 541 are adapted such that the one or
more optical cables 110, 410, 510 can be installed in and
subsequently removed from the carrier 130, 430, 530 and frame 140,
440, 540 without damage to the carrier 130, 430, 530, frame 140,
440, 540, and/or the optical cables 110, 410, 510.
[0063] FIG. 6 is a flow diagram of a method of implementing an
optical connector in accordance with some embodiments. One or more
optical cables are inserted 610 into a housing comprising a carrier
and frame. Each optical cable comprises at least one optical
waveguide and at least one optical ferrule attached to the
waveguide. An actuator is operated 620 that moves 630 the carrier
relative to the frame. In response to the relative movement between
the carrier and the frame, the optical waveguide bends 640 or bends
more and the ferrules rotate. The bend in the optical waveguide
provides a predetermined spring force at a predetermined angle of
the ferrule when the ferrule is mated with a mating ferrule. In
some embodiments, the housing includes a first housing portion and
a second housing portion that comprises the carrier and the frame.
Operating the actuator comprises mechanically engaging the first
housing portion with the second housing portion. According to some
implementations, mechanically engaging the first housing portion
with the second housing portion is performed independently of
operating the actuator. For example, operating the actuator may be
performed after the first housing portion is fully engaged with the
second housing portion. Operating the actuator can involve
operating a cam or other structure that engages with a surface of
the carrier; this may be done manually, for example by turning an
external knob or screw head. The carrier is moved relative to the
frame in response to engaging the cam with a surface of the
carrier.
[0064] In some implementations, mechanically engaging the first
housing portion and the second housing portion comprises moving one
or both of the first housing portion and the second housing portion
along a lateral axis substantially orthogonal to a mating axis of
the optical connector. In some implementations, mechanically
engaging the first housing portion and the second housing portion
comprises rotating one or both of the first housing portion and the
second housing portion around a vertical axis substantially
orthogonal to a mating axis of the optical connector. In other
implementations mechanically engaging the first housing portion and
the second housing portion comprises rotating one or both of the
first housing portion and the second housing portion around a
longitudinal axis substantially parallel to a mating axis of the
optical connector. In yet other implementations, mechanically
engaging the first housing portion and the second housing portion
comprises moving one or both of the first and second housing
portions along a longitudinal axis substantially parallel to a
mating axis of the optical connector.
[0065] According to some versions of the method, multiple optical
cables can be inserted into the housing simultaneously. In these
versions, the multiple optical cables may comprise a common cable
retainer. Alternatively, each optical cable can have a separate
cable retainer and/or can be separately inserted into the housing.
Inserting the optical cables can involve inserting the cable
retainer into a retainer mount of the frame. In some embodiments,
each optical cable is attached to a corresponding cable retainer.
According to some versions of the method, the optical cables can be
inserted into the carrier and attached to the carrier.
Subsequently, the carrier is inserted into the second housing
portion.
[0066] The connector structures herein are configured such that the
one or more optical cables are inserted into the carrier and the
frame while the optical cables are substantially straight or are
slightly bend. The optical cables are inserted into the carrier and
the frame along a first insertion axis. For example, the first
insertion axis may be substantially orthogonal or may be
substantially parallel to a mating of the optical connector.
According to some embodiments, the first insertion axis is a
longitudinal axis substantially parallel to a mating axis of the
optical connector. In some implementations, insertion the optical
cables may involve inserting the optical cables along multiple
orthogonal axes. After insertion of the optical cables into the
carrier and frame, the actuator is operated which causes the
carrier to move relative to the frame along a configuration axis.
According to some embodiments the configuration axis is
substantially orthogonal to at least one of the insertion axes.
[0067] Embodiments disclosed herein include; [0068] Embodiment 1.
An optical connector comprising: [0069] one or more optical cables,
each optical cable comprising an array of at least one optical
waveguide and at least one optical ferrule attached to the array of
optical waveguides; and [0070] a housing comprising: [0071] a first
housing portion; and [0072] a second housing portion engaged with
the first housing portion, the second housing portion comprising at
least one carrier and a frame, the carrier and frame of the second
housing portion configured to support the one or more optical
cables, the first housing portion and the second housing portion
configured such that mechanical engagement of the first housing
portion with the second housing portion moves the carrier relative
to the frame, movement of the carrier relative to the frame causing
a bend in each optical waveguide and rotation of each ferrule, the
bend providing a predetermined spring force of the optical
waveguide at a predetermined angle of the ferrule. [0073]
Embodiment 2. The optical connector of embodiment 1, wherein the
one or more optical cables are attached to the carrier by adhesive.
[0074] Embodiment 3. The optical connector of embodiment 1, wherein
the optical cables are attached to the carrier by a friction grip.
[0075] Embodiment 4. The optical connector of any of embodiments 1
through 3, wherein there is one carrier per frame. [0076]
Embodiment 5. The optical connector of any of embodiments 1 through
3, wherein there are multiple carriers per frame. [0077] Embodiment
6. The optical connector of any of embodiments 1 through 5, wherein
there are multiple frames per connector; [0078] Embodiment 7. The
optical connector of any of embodiments 1 through 6, wherein:
[0079] at least one cable retainer is attached to the array of
waveguides of the one or more optical cables and spaced apart from
ferrules of the optical cables; and [0080] the carrier includes at
least one retainer mount configured to receive the at least one
cable retainer. [0081] Embodiment 8. The optical connector of
embodiment 7, wherein the at least one cable retainer is a single
cable retainer attached to the waveguides of each of the multiple
optical cables. [0082] Embodiment 9. The optical connector of
embodiment 7, wherein: [0083] the at least one cable retainer
comprises multiple cable retainers; and [0084] the one or more
optical cables comprises multiple optical cables, wherein each of
the multiple cable retainers is respectively attached to the at
least one waveguide of one of the multiple optical cables. [0085]
Embodiment 10. The optical connector of embodiment 7, wherein the
optical cables are attached to the cable retainer by adhesive.
[0086] Embodiment 11. The optical connector of embodiment 7,
wherein the optical cables are attached to the cable retainer by a
friction grip. [0087] Embodiment 12. The optical connector of any
of embodiments 1 through 11, wherein; [0088] the one or more
optical cables includes multiple optical cables, each optical cable
comprising a cable retainer attached to the array of waveguides of
the optical cable and spaced apart from the ferrule of the optical
cable; and [0089] the carrier includes multiple retainer mounts,
each retainer mount configured to receive a corresponding cable
retainer of the multiple optical cables. [0090] Embodiment 13. The
optical connector of any of embodiments 1 through 12, wherein the
at least one optical waveguide array comprises at least one optical
fiber. [0091] Embodiment 14. The optical connector of any of
embodiments 1 through 12, wherein the at least one optical
waveguide array comprises multiple optical fibers. [0092]
Embodiment 15. The optical connector of any of embodiments 1
through 12, wherein the at least one optical waveguide array
comprises at least one planar waveguide disposed on a substrate.
[0093] Embodiment 16. The optical connector of any of embodiments 1
through 12, wherein the at least one optical waveguide array
comprises multiple planar waveguides disposed on a substrate.
[0094] Embodiment 17. The optical connector of any of embodiments 1
through 16 1, wherein the frame includes one or more ferrule
supports disposed at a mating end of the optical connector, the
ferrule supports configured to support the ferrules of the optical
cables. [0095] Embodiment 18. The optical connector of any of
embodiments 1 through 17, wherein the one or more optical cables
includes at least four optical cables, the optical cables extending
along a longitudinal axis of the connector and stacked within the
connector housing along a vertical axis different from the
longitudinal axis. [0096] Embodiment 19. The optical connector of
any of embodiments 1 through 18, wherein the frame includes one or
more frame waveguide support walls disposed between a mating end of
the optical connector and the carrier, each frame waveguide support
wall configured to support a corresponding optical waveguide.
[0097] Embodiment 20. The optical connector of embodiment 19,
wherein the each frame waveguide support wall includes a sloped
portion that supports the optical waveguide such that the optical
waveguide makes a predetermined angle with respect to a mating axis
of the optical connector. [0098] Embodiment 21. The optical
connector of embodiment 20, wherein the predetermined angle is
between 15 and 25 degrees. [0099] Embodiment 22. The optical
connector of embodiment 20, wherein the predetermined angle is
about 18 degrees. [0100] Embodiment 23. The optical connector of
any of embodiments 1 through 22, wherein the carrier includes one
or more carrier waveguide support walls disposed between a mating
end of the optical connector and a retainer mount of the carrier,
each carrier waveguide support wall configured to support a
corresponding optical waveguide. [0101] Embodiment 24. The optical
connector of embodiment 23, wherein the each carrier waveguide
support wall includes a sloped portion that supports the optical
waveguide such that the optical waveguide makes a predetermined
angle with respect to a mating axis of the optical connector.
[0102] Embodiment 25. The optical connector of embodiment 24,
wherein the predetermined angle is between 15 and 25 degrees.
[0103] Embodiment 26. The optical connector of embodiment 24,
wherein the predetermined angle is about 18 degrees. [0104]
Embodiment 27. The optical connector of any of embodiments 1
through 26, wherein before engagement of the first and second
housing portions, the carrier and the frame are adapted to allow
the optical cables to be installed in and subsequently removed from
the carrier and the frame without damage to the carrier, frame or
the optical cables. [0105] Embodiment 28. The optical connector of
any of embodiments 1 through 27, wherein: [0106] the housing is
configured to allow insertion of the optical cables into the
carrier and the frame before engagement of the first housing
portion and the second housing portion while waveguides of the
optical cables are substantially straight or slightly bent; and
[0107] mechanical engagement of the first housing portion with the
second housing portion causes the waveguides to bend or to bend
more. [0108] Embodiment 29. The optical connector of any of
embodiments 1 through 28, wherein: [0109] the second housing
portion is configured to allow insertion of the optical cables into
the carrier and the frame along at least a first insertion axis;
and [0110] the first housing portion and the second housing portion
are configured such that mechanical engagement of the first housing
portion with the second housing portion causes the carrier to move
relative to the frame along a configuration axis. [0111] Embodiment
30. The optical connector of embodiment 29, wherein the first
insertion axis is a lateral axis substantially orthogonal to a
mating axis of the optical connector. [0112] Embodiment 31. The
optical connector of embodiment 29, wherein the configuration axis
is a vertical axis substantially perpendicular to a mating axis of
the optical connector. [0113] Embodiment 32. The optical connector
of embodiment 29, wherein the second housing portion is configured
to allow insertion of the optical cables into the carrier and the
frame along the first insertion axis and along a second insertion
axis that is substantially orthogonal to the first insertion axis.
[0114] Embodiment 33. The optical connector of embodiment 32,
wherein the first insertion axis is a lateral axis substantially
orthogonal to a mating axis of the optical connector and the second
insertion axis is a longitudinal axis substantially parallel to a
mating axis of the optical connector. [0115] Embodiment 34. The
optical connector of embodiment 29, wherein the configuration axis
is substantially orthogonal to the first insertion axis. [0116]
Embodiment 35. The optical connector of embodiment 29, wherein the
configuration axis is a vertical axis substantially orthogonal to
the mating axis. [0117] Embodiment 36. The optical connector of any
of embodiments 1 through 35, wherein: [0118] the frame and the
carrier are configured to allow insertion of the optical cable into
the frame and the carrier along a first insertion axis and a second
insertion axis orthogonal to the first insertion axis before
mechanical engagement of the first housing portion and the second
housing portion; and [0119] mechanical engagement of the first
housing portion with the second housing portion causes the carrier
to move relative to the frame along a configuration axis that is
different from the first insertion axis and the second insertion
axis. [0120] Embodiment 37. The optical connector of embodiment 36,
wherein: [0121] the first insertion axis is a lateral axis
substantially orthogonal to a mating axis of the optical connector;
[0122] the second insertion axis is a longitudinal axis
substantially parallel to the mating axis of the optical connector;
and [0123] the configuration axis is a third axis substantially
orthogonal to the mating axis. [0124] Embodiment 38. The optical
connector of any of embodiments 1 through 37, wherein the first
housing portion and the second housing portion are configured such
that mechanical engagement of the first housing portion with the
second housing portion includes relative movement between the first
housing portion and the second housing portion along at least a
first engagement axis. [0125] Embodiment 39. The optical connector
of embodiment 38, wherein the engagement axis is a longitudinal
axis substantially parallel to a mating axis of the optical
connector. [0126] Embodiment 40. The optical connector of
embodiment 38, wherein the engagement axis is a lateral axis
substantially orthogonal to a mating axis of the optical connector.
[0127] Embodiment 41. The optical connector of any of embodiments 1
through 40, wherein the first housing portion and the second
housing portion are configured such that mechanical engagement of
the first and second housing portions includes rotational movement
of the first housing portion and the second housing portion around
a rotational engagement axis. [0128] Embodiment 42. The optical
connector of embodiment 41, wherein the rotational axis is a
vertical axis substantially orthogonal to a mating axis of the
optical connector. [0129] Embodiment 43. The optical connector of
embodiment 41, wherein the rotational axis is a longitudinal axis
substantially parallel to a mating axis of the optical connector.
[0130] Embodiment 44. An optical connector comprising: [0131] one
or more optical cables each optical cable comprising an array of at
least one optical waveguide and at least one optical ferrule
attached to the array of optical waveguides; [0132] a housing
comprising at least one carrier and a frame, the carrier and the
frame configured to support the one or more optical cables; and
[0133] an actuator configured such that operation of the actuator
causes relative motion between the carrier and the frame, the
relative motion between the carrier and the frame causing a bend in
the optical waveguide and rotation of the ferrule, the bend
providing a predetermined spring force of the waveguide at a
predetermined angle of the ferrule with respect to a mating axis of
the optical connector. [0134] Embodiment 45. The optical connector
of embodiment 44, wherein the housing includes a first housing
portion and a second housing portion engaged with the first housing
portion, the second housing portion comprising the carrier and the
frame. [0135] Embodiment 46. The optical connector of embodiment
45, wherein the actuator is configured such that operation of the
actuator occurs as the first housing portion mechanically engages
with the second housing portion. [0136] Embodiment 47. The optical
connector of claim 45, wherein the actuator is configured to be
operated independently from mechanical engagement of the first
housing portion with the second housing portion. [0137] Embodiment
48. The optical connector of embodiment 45, wherein the actuator is
configured to be manually operated after engagement of the first
housing portion with the second housing portion. [0138] Embodiment
49. The optical connector of embodiment 45, wherein the actuator is
configured to be reversibly operated such that reverse operation of
the actuator straightens the bend in the optical waveguide. [0139]
Embodiment 50. The optical connector of embodiment 45, wherein the
actuator is disposed on the first housing portion, the second
housing portion, or on both the first and the second housing
portions. [0140] Embodiment 51. The optical connector of embodiment
45, wherein at least a portion of the actuator is disposed on the
carrier. [0141] Embodiment 52. The optical connector of embodiment
45, wherein at least a portion of the actuator is disposed on the
frame. [0142] Embodiment 53. The optical connector of any of
embodiments 44 through 52, wherein before operation of the actuator
the carrier and the frame are adapted to allow the optical cables
to be installed in and subsequently removed from the second housing
portion without damage to the second housing portion and the
optical cables. [0143] Embodiment 54. The optical connector of any
of embodiments 44 through 53, wherein: [0144] the second housing
portion is configured to allow insertion of the optical cables into
the carrier and the frame along at least a first insertion axis;
and [0145] the actuator is configured such that operation of the
actuator causes the carrier to move relative to the frame along a
configuration axis. [0146] Embodiment 55. The optical connector of
embodiment 54, wherein the configuration axis is substantially
orthogonal to the first insertion axis. [0147] Embodiment 56. The
optical connector of embodiment 54, wherein the first insertion
axis is a lateral axis substantially orthogonal to a mating axis of
the optical connector. [0148] Embodiment 57. The optical connector
of embodiment 54, wherein the first insertion axis is a
longitudinal axis substantially parallel to a mating axis of the
optical connector.
[0149] Embodiment 58. The optical connector of embodiment 54,
wherein the configuration axis is a vertical axis substantially
orthogonal to a mating axis of the optical connector. [0150]
Embodiment 59. The optical connector of embodiment 54, wherein the
configuration axis is a longitudinal axis (196) substantially
parallel to a mating axis of the optical connector. [0151]
Embodiment 60. The optical connector of embodiment 54, wherein the
second housing portion is configured to allow insertion of the
optical cables into the carrier and the frame along the first
insertion axis and along a second insertion axis. [0152] Embodiment
61. The optical connector of embodiment 60, wherein the first
insertion axis is a lateral axis substantially orthogonal to a
mating axis of the optical connector and the second insertion axis
is a longitudinal axis substantially parallel to the mating axis.
[0153] Embodiment 62. The optical connector of any of embodiments
44 through 61, wherein: [0154] the carrier and the frame are
configured to allow insertion of the optical cables into the frame
and the carrier along a first insertion axis and a second insertion
axis orthogonal to the first insertion axis before the mechanical
engagement of the first housing portion and the second housing
portion; and [0155] the actuator is configured such that operation
of the actuator causes the carrier to move relative to the frame
along a configuration axis. [0156] Embodiment 63. The optical
connector of embodiment 62, wherein: [0157] the first insertion
axis is a lateral axis substantially orthogonal to a mating axis of
the optical connector and the second insertion axis is a
longitudinal axis substantially parallel to the mating axis of the
optical connector; and [0158] the first configuration axis is a
vertical axis substantially orthogonal to the mating axis. [0159]
Embodiment 64. The optical connector of any of embodiments 44
through 63, wherein: [0160] the housing includes a first housing
portion engaged with a second housing portion that includes the
carrier and the frame; and [0161] the actuator comprises a rib
disposed on the first housing portion, the rib configured to
interact with a surface of the carrier to cause the relative motion
between the carrier and the frame during mechanical engagement of
the first housing portion and the second housing portion. [0162]
Embodiment 65. The optical connector of embodiment 64, wherein the
rib includes an inclined surface. [0163] Embodiment 66. The optical
connector of embodiment 65, wherein the surface of the carrier
includes an inclined surface that is complementary to the inclined
surface of the rib. [0164] Embodiment 67. The optical connector of
any of embodiments 44 through 66, wherein: [0165] the housing
includes a first housing portion engaged with a second housing
portion that includes the carrier and the frame; and [0166] the
actuator comprises a surface of the carrier, the surface configured
to interact with a rib of the first housing portion to cause the
relative motion between the carrier and the frame during mechanical
engagement of the first housing portion and the second housing
portion. [0167] Embodiment 68. The optical connector of any of
embodiments 44 through 66, wherein the actuator comprises a tapered
surface of the first housing portion and a surface of the carrier,
wherein engagement of the tapered surface of the first housing
portion with the surface of the carrier causes relative motion
between the carrier and the frame. [0168] Embodiment 69. The
optical connector of any of embodiments 44 through 66, wherein the
actuator comprises a cam disposed in the housing and a surface of
the carrier, wherein engagement of the cam with the surface of the
carrier causes the relative motion between the carrier and the
frame. [0169] Embodiment 70. An optical connector comprising:
[0170] one or more optical cables, each optical cable comprising am
array of at least one optical waveguide and at least one optical
ferrule attached to the optical waveguide; and [0171] a housing
that includes one or more waveguide support walls, each waveguide
support wall configured to allow the optical cables to be inserted
into the housing when waveguides of the optical cables are in a
substantially straight configuration, each waveguide support wall
having a sloped surface to support the waveguides at a
predetermined angle to a mating axis of the optical connector after
the waveguides bend within the housing. [0172] Embodiment 71. The
optical connector of embodiment 70, wherein the predetermined angle
is between about 15 and about 25 degrees. [0173] Embodiment 72. The
optical connector of embodiment 70, wherein the predetermined angle
is about 18 degrees. [0174] Embodiment 73. The optical connector of
any of embodiments 70 through 72, wherein the waveguide support
walls are adapted such that the one or more optical cables can be
installed in and subsequently removed from the frame without damage
to the frame or the optical cables. [0175] Embodiment 74. The
optical connector of any of embodiments 70 through 73, wherein the
housing includes a carrier and a frame configured to move relative
to one another, movement of the carrier relative to the frame
causing the waveguides to bend. [0176] Embodiment 75. The optical
connector of embodiment 74, wherein the waveguide support walls are
disposed in one or both of the carrier and the frame. [0177]
Embodiment 76. The optical connector of embodiment 74, wherein the
waveguide support walls include one or more waveguide support walls
on the carrier. [0178] Embodiment 77 The optical connector of
embodiment 74, wherein the waveguide support walls include one or
more waveguide support walls on the frame. [0179] Embodiment 78.
The optical connector of claim 74, wherein: [0180] each optical
cable includes a cable retainer spaced apart from the ferrule and
attached to the waveguide; and [0181] the carrier includes at least
one retainer mount configured to receive the cable retainer. [0182]
Embodiment 79. The optical connector of embodiment 78, wherein:
[0183] the housing includes a carrier and a frame configured to
move relative to one another; and [0184] the retainer mount is
disposed in the carrier such that movement of the carrier relative
to the frame causes the waveguides to bend. [0185] Embodiment 80.
The optical connector of any of embodiments 70 through 79, wherein
the housing comprises: [0186] a first housing portion; and [0187] a
second housing portion engaged with the first housing portion, the
second housing portion comprising a carrier and the frame
configured to move relative to one another, engagement of the first
housing portion with the second housing portion causing the
relative movement of the carrier and the frame, the relative
movement of the carrier and the frame causing the waveguides to
bend within the housing. [0188] Embodiment 81. The optical
connector of any of embodiments 70 through 80, wherein each
waveguide support wall includes a face that is spaced apart from a
mating face of the optical connector. [0189] Embodiment 82. An
optical connector comprising: [0190] one or more optical cables,
each optical cable comprising an array of at least one optical
waveguide and at least one optical ferrule attached to the optical
waveguide array; and [0191] a housing comprising one or more
waveguide support walls configured to support the optical cables,
the one or more waveguide support walls configured to allow the
optical cables to be inserted into the housing along a direction
substantially orthogonal to a mating axis of the optical connector.
[0192] Embodiment 83. The optical connector of embodiment 82,
wherein each waveguide support wall includes a sloped surface
configured to support the optical waveguide of the optical cable at
a predetermined angle with respect to a mating axis of the optical
connector. [0193] Embodiment 84. The optical connector of any of
embodiments 82 through 83, wherein the housing includes a carrier
and a frame configured to move relative to one another and one or
both of the carrier and the frame include the waveguide support
walls. [0194] Embodiment 85. The optical connector of embodiment
84, wherein the one or more waveguide support walls are configured
to allow the optical cables to be inserted into the carrier and
frame in a substantially straight or slightly bent configuration
and relative movement between the carrier and the frame causes the
optical waveguides to bend or to bend more. [0195] Embodiment 86.
An optical cable comprising: [0196] An array of at least one
optical waveguide having a longitudinal axis; [0197] at least one
optical ferrule attached to the array of optical waveguides; and
[0198] a cable retainer attached to the optical waveguide and
spaced apart from the ferrule, wherein when the optical waveguide
is held by the cable retainer so that the portion of the optical
waveguide at the cable retainer is horizontally straight with
respect to gravity, the portion of the optical waveguide at the
ferrule sags by less than a predetermined percentage, x %, of a
distance, d, between the cable retainer and the optical ferrule.
[0199] Embodiment 87. The optical cable of embodiment 86, wherein
the x % is about 20%. [0200] Embodiment 88. The optical cable of
embodiment 86, wherein x % is about 10%. [0201] Embodiment 89. The
optical cable of embodiment 86, wherein x % is about 5%. [0202]
Embodiment 90. The optical cable of embodiment 86, wherein x % is
about 1%. [0203] Embodiment 91. The optical cable of embodiment 86,
wherein the distance is about 4 cm. [0204] Embodiment 92. The
optical cable of embodiment 86, wherein the distance is about 1.8
cm. [0205] Embodiment 93. The optical cable of embodiment 86,
wherein the at least one optical waveguide comprises an optical
fiber. [0206] Embodiment 94. The optical cable of embodiment 86,
wherein the at least one optical waveguide comprises a waveguide
array of multiple optical fibers. [0207] Embodiment 95. The optical
cable of embodiment 86, wherein the at least one optical waveguide
comprises at least one planar waveguide disposed on a substrate.
[0208] Embodiment 96. The optical cable of embodiment 86, wherein
the at least one optical waveguide comprises multiple planar
waveguides disposed on a substrate. [0209] Embodiment 97. A method
of assembling an optical connector comprising: [0210] inserting one
or more optical cable into housing comprising a carrier and frame,
each optical cable comprising at least one optical waveguide and at
least one optical ferrule; [0211] operating an actuator; [0212]
moving the carrier relative to the frame in response to operating
the actuator; and [0213] bending the optical waveguide and rotating
the ferrule in response to movement of the carrier relative to the
frame, the bending of the optical waveguide providing a
predetermined spring force at a predetermined angle of the ferrule.
[0214] Embodiment 98. The method of embodiment 97, wherein: [0215]
the housing includes a first housing portion and a second housing
portion that comprises the frame and the actuator; and [0216]
operating the actuator comprises mechanically engaging the first
housing portion with the second housing portion. [0217] Embodiment
99. The method of any of embodiments 97 through 98, wherein: [0218]
the housing portion includes a first housing portion and a second
housing portion that comprises the frame and the actuator; and
[0219] the method further comprising: [0220] mechanically engaging
the first housing portion with the second housing portion; and
[0221] after mechanically engaging the first housing portion with
the second housing portion, operating the actuator. [0222]
Embodiment 100. The method of embodiment 99, wherein mechanically
engaging the first housing portion and the second housing portion
comprises moving one or both of the first housing portion and the
second housing portion along a lateral axis substantially
orthogonal to a mating axis of the optical connector. [0223]
Embodiment 101. The method of embodiment 99, wherein mechanically
engaging the first housing portion and the second housing portion
comprises rotating one or both of the first housing portion and the
second housing portion around a vertical axis substantially
orthogonal to a mating axis of the optical connector. [0224]
Embodiment 102. The method of embodiment 99, wherein mechanically
engaging the first housing portion and the second housing portion
comprises rotating one or both of the first housing portion and the
second housing portion around a longitudinal axis substantially
parallel to a mating axis of the optical connector. [0225]
Embodiment 103. The method of embodiment 99, wherein mechanically
engaging the first housing portion and the second housing portion
comprises moving one or both of the first and second housing
portions along a longitudinal axis substantially parallel to a
mating axis of the optical connector. [0226] Embodiment 104. The
method of any of embodiments 97 through 103, wherein: [0227] the
housing includes a first housing portion and a second housing
portion that comprises the carrier and the frame; [0228] operating
the actuator comprises operating a cam that engages with a surface
of the carrier; and [0229] moving the carrier relative to the frame
comprises moving the carrier relative to the frame in response to
engaging the cam with a surface of the carrier. [0230] Embodiment
105. The method of any of embodiments 97 through 104, wherein
inserting the one or more optical cables comprises simultaneously
inserting multiple optical cables. [0231] Embodiment 106. The
method of any of embodiments 97 through 105, wherein: [0232] each
optical cable includes a cable retainer attached to the waveguides;
and [0233] inserting the one or more optical cables comprises
inserting the cable retainer into a retainer mount of the frame.
[0234] Embodiment 107. The method of embodiment 106, wherein one
cable retainer is attached to multiple arrays of optical
waveguides, each array of optical waveguides attached to a
corresponding optical ferrule. [0235] Embodiment 108 The method of
any of embodiments 97 through 107, wherein inserting the one or
more optical cables comprises: [0236] inserting the optical cables
into the carrier; and [0237] subsequently inserting the carrier
into the frame. [0238] Embodiment 109. The method of any of
embodiments 97 through 108, further comprising removing the one or
more optical cables from the housing without damage to the housing
or the optical cables. [0239] Embodiment 110. The method of any of
embodiments 97 through 109, wherein inserting the one or more
optical cables comprises inserting the one or more optical cables
into the carrier and the frame while the optical waveguides are
substantially straight or are slightly bent. [0240] Embodiment 111.
The optical connector of any of embodiments 97 through 110,
wherein:
[0241] inserting the optical cables comprises inserting the optical
cables into the carrier and the frame along at least a first
insertion axis; and [0242] moving the carrier relative to the frame
in response to operating the actuator comprises moving the carrier
relative to the frame along a configuration axis orthogonal to the
first insertion axis. [0243] Embodiment 112. The optical connector
of embodiment 111, wherein the first insertion axis is a lateral
axis substantially orthogonal to a mating of the optical connector.
[0244] Embodiment 113. The optical connector of embodiment 111,
wherein the first insertion axis is a longitudinal axis
substantially parallel to a mating axis of the optical connector.
[0245] Embodiment 114. The optical connector of embodiment 111,
wherein inserting the optical cables comprises inserting the
optical cables into the carrier and the frame along the first
insertion axis and along a second insertion axis, wherein the first
insertion axis is a lateral axis that is substantially orthogonal
to a mating axis of the optical connector and the second insertion
axis is a longitudinal axis that is substantially parallel to the
mating axis. [0246] Embodiment 115. The optical connector of
embodiment 111, wherein the configuration axis is a vertical axis
substantially orthogonal to a mating axis of the optical
connector.
[0247] Unless otherwise indicated, all numbers expressing feature
sizes, amounts, and physical properties used in the specification
and claims are to be understood as being modified in all instances
by the term "about." Accordingly, unless indicated to the contrary,
the numerical parameters set forth in the foregoing specification
and attached claims are approximations that can vary depending upon
the desired properties sought to be obtained by those skilled in
the art utilizing the teachings disclosed herein. The use of
numerical ranges by endpoints includes all numbers within that
range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and
any range within that range.
[0248] Various modifications and alterations of the embodiments
discussed above will be apparent to those skilled in the art, and
it should be understood that this disclosure is not limited to the
illustrative embodiments set forth herein. The reader should assume
that features of one disclosed embodiment can also be applied to
all other disclosed embodiments unless otherwise indicated. It
should also be understood that all U.S. patents, patent
applications, patent application publications, and other patent and
non-patent documents referred to herein are incorporated by
reference, to the extent they do not contradict the foregoing
disclosure.
* * * * *